U.S. patent application number 11/114066 was filed with the patent office on 2006-03-02 for bicycle generator hub.
This patent application is currently assigned to Shimano Inc.. Invention is credited to Takahiro Endo, Kazuki Tanaka.
Application Number | 20060043807 11/114066 |
Document ID | / |
Family ID | 34937717 |
Filed Date | 2006-03-02 |
United States Patent
Application |
20060043807 |
Kind Code |
A1 |
Tanaka; Kazuki ; et
al. |
March 2, 2006 |
Bicycle generator hub
Abstract
A bicycle generator hub is mounted to the front fork of a
bicycle and includes a hub shaft, a hub shell, bearings, a
generator mechanism and first and second magnetic flux
recirculation members. The hub shaft is non-rotatably mounted to
the front fork. The hub shell is disposed around the surface of the
hub shaft. The bearings are disposed between the hub shell and the
hub shaft to enable the hub shell to rotate relative to the hub
shaft. The generator mechanism has a coil mounted to the hub shaft
and a magnet unit disposed such that the generator mechanism
generates electric power via the rotation of the hub shell relative
to the hub shaft. The first and second magnetic flux recirculation
members are disposed on the hub shaft or the hub shell and return a
leaked magnetic flux to the coil.
Inventors: |
Tanaka; Kazuki; (Sakai,
JP) ; Endo; Takahiro; (Sakai, JP) |
Correspondence
Address: |
SHINJYU GLOBAL IP COUNSELORS, LLP
1233 20TH STREET, NW, SUITE 700
WASHINGTON
DC
20036-2680
US
|
Assignee: |
Shimano Inc.
Sakai
JP
|
Family ID: |
34937717 |
Appl. No.: |
11/114066 |
Filed: |
April 26, 2005 |
Current U.S.
Class: |
310/75C |
Current CPC
Class: |
B62J 6/12 20130101 |
Class at
Publication: |
310/075.00C |
International
Class: |
H02K 7/10 20060101
H02K007/10; H02K 7/18 20060101 H02K007/18; B62J 6/08 20060101
B62J006/08 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 31, 2004 |
JP |
2004-252423 |
Claims
1. A bicycle generator hub comprising: a hub shaft configured and
arranged to be non-rotatably mounted to a bicycle frame; a hub
shell rotatably mounted around the hub shaft; first and second
bearings disposed between the hub shell and the hub shaft; a
generator mechanism having a coil mounted to the hub shaft and a
plurality of magnets disposed opposite the coil on an inner
circumferential surface of the hub shell to generate electric power
from rotation of the hub shell relative to the hub shaft; and first
and second magnetic flux recirculation members disposed on one of
the hub shaft and the hub shell to return a leaked magnetic flux to
the coil, the first and second magnetic flux recirculation members
being free from direct contact with a coil member.
2. The bicycle generator hub according to claim 1, wherein the hub
shaft is formed of a magnetic metal.
3. The bicycle generator hub according to claim 1, wherein the hub
shell includes a cylindrical member with the magnets of the
generator mechanism mounted thereto.
4. The bicycle generator hub according to claim 3, wherein the hub
shell has first and second cap members that are disposed between
the cylindrical member and the first and second bearings,
respectively.
5. The bicycle generator hub according to claim 4, wherein the
first and second magnetic flux recirculation members are disposed
on the first and second cap members, respectively, and extend
toward the coil.
6. The bicycle generator hub according to claim 4, wherein the
first and second magnetic flux recirculation members are integrally
formed with the first and second cap members, respectively.
7. The bicycle generator hub according to claim 4, wherein the
first and second magnetic flux recirculation members extend from
the coil toward the first and second cap members, respectively.
8. The bicycle generator hub according to claim 4, wherein the
cylindrical member is made of an aluminum alloy, and the first and
second cap members are made of an iron-based metal.
9. The bicycle generator hub according to claim 4, wherein the
cylindrical member and the first and second cap members are made of
an iron-based metal.
10. The bicycle generator hub according to claim 3, wherein the
first and second magnetic flux recirculation members are mounted to
the hub shaft and extend toward the coil.
11. The bicycle generator hub according to claim 1, wherein each of
the first and second magnetic flux recirculation members has an end
portion that is disposed proximate to the coil.
12. The bicycle generator hub according to claim 1, wherein each of
the first and second magnetic flux recirculation members has a
first end portion that contacts the coil and a second end portion
that is disposed proximate to one of the hub shell and the hub
shaft.
13. The bicycle generator hub according to claim 11, wherein the
first and second magnetic flux recirculation members are made of an
iron-based metal.
14. The bicycle generator hub according to claim 12, wherein the
first and second magnetic flux recirculation members are made of an
iron-based metal.
15. The bicycle generator hub according to claim 11, wherein the
first and second magnetic flux recirculation members are annular
and disposed around the hub shaft.
16. The bicycle generator hub according to claim 12, wherein the
first and second magnetic flux recirculation members are annular
and disposed around the hub shaft.
17. The bicycle generator hub according to claim 11, wherein the
first and second magnetic flux recirculation members have
rod-shaped members.
18. The bicycle generator hub according to claim 12, wherein the
first and second magnetic flux recirculation members have
rod-shaped members.
19. The bicycle generator hub according to claim 13, wherein the
first and second magnetic flux recirculation members have
rod-shaped members.
20. The bicycle generator hub according to claim 4, wherein each of
the first and second cap members of the hub shell is bent towards
the coil to form the first and second magnetic flux recirculation
members, respectively, such that each of the first and second
magnetic flux recirculation members has an end portion that is
disposed proximate to the coil.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Japanese Patent
Application No. 2004-252423. The entire disclosure of Japanese
Patent Application No. 2004-252423 is hereby incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention generally relates to a bicycle generator hub.
More specifically, the present invention relates to a bicycle
generator hub that rotatably mounts a wheel to a bicycle frame and
generates power via the rotation of the wheel.
[0004] 2. Background Information
[0005] Bicycling is becoming an increasingly more popular form of
recreation as well as a means of transportation. Moreover,
bicycling has become a very popular competitive sport for both
amateurs and professionals. Whether the bicycle is used for
recreation, transportation or competition, the bicycle industry is
constantly improving various components of the bicycle. One
component that has been extensively redesigned is the bicycle
hub.
[0006] In general, a bicycle hub has an axle or a hub shaft that is
detachably and non-rotatably mounted to a bicycle frame. A
cylindrical hub shell is rotatably mounted to the hub shaft.
Bearings rotatably support the hub shell around the hub shaft. The
hub shell is connected to the rim of the wheel by spokes.
[0007] A bicycle hub having the above construction and a generator
mechanism with a power source incorporated into the hub shell is
known in the conventional art (See, Japanese Laid-Open Publication
No. H09-132185). In the bicycle generator hub of the prior art, the
generator mechanism is placed between the hub shaft and the hub
shell. Specifically, a coil is non-rotatably mounted to the hub
shaft and magnets are mounted to the inner circumferential surface
of the hub shell. The hub shell is used as a yoke that serves as a
magnetic path for the magnets. In order to reduce costs, the hub
shell is made of iron.
[0008] The magnets and coil are surrounded by a magnetic member in
that the magnetic iron hub shell also serves as a yoke. Therefore,
it is difficult for a magnetic flux, which is generated by the
magnets, to become concentrated in the coil. This reduces the power
generation efficiency.
[0009] In view of the above, it will be apparent to those skilled
in the art from this disclosure that there exists a need for an
improved bicycle generator hub that facilitates the concentration
of the magnetic flux in the coil. This invention addresses this
need in the art as well as other needs, which will become apparent
to those skilled in the art from this disclosure.
SUMMARY OF THE INVENTION
[0010] One object of the present invention is to reduce costs by
maximizing the power generation efficiency in a bicycle generator
hub.
[0011] The bicycle generator hub pertaining to a first aspect of
the present invention is a bicycle generator hub that includes a
hub shaft, a hub shell, first and second bearings, a generator
mechanism and first and second magnetic flux recirculation members.
The hub shaft is configured and arranged to be non-rotatably
mounted to a bicycle frame. The hub shell is rotatably mounted
around the hub shaft. The first and second bearings are disposed
between the hub shell and the hub shaft. The generator mechanism
has a coil mounted to the hub shaft. The generator mechanism has
magnets that are disposed opposite the coil on an inner
circumferential surface of the hub shell. The generator mechanism
generates electric power from rotation of the hub shell relative to
the hub shaft. The first and second magnetic flux recirculation
members are disposed on either the hub shaft or the hub shell to
return a leaked magnetic flux to the coil.
[0012] In the bicycle generator hub of the first aspect of the
present invention, the magnets rotate together with the hub shell.
When the hub shell rotates, the magnetic flux that is generated by
the magnets passes through the coil, thereby generating electric
power in the coil. During the rotation, the magnetic flux that
leaks from the coil to the outside is returned to the coil via the
first and second magnetic flux recirculation members. This results
in a large amount of magnetic flux passing through the coil. As a
result, regardless of the material of the hub shell, the amount of
magnetic flux passing through the coil increases. This maximizes
the power generation efficiency and reduces costs.
[0013] The bicycle generator hub pertaining to a second aspect of
the present invention is the bicycle generator hub according to the
first aspect of the present invention, wherein the hub shaft is
made of a magnetic metal. In this case, the first and second
magnetic flux recirculation members easily recirculate the magnetic
flux through the hub shaft to the coil.
[0014] The bicycle generator hub pertaining to a third aspect of
the present invention is the bicycle generator hub according to the
first or second aspects of the present invention, wherein the hub
shell includes an essentially cylindrical member. The magnets are
mounted to the cylindrical member of the hub shell. The hub shell
further includes first and second cap members that are disposed
between the cylindrical member and the first and second bearings.
The cylindrical member and the first and second cap members are
made of different materials. The first and second cap members are
made of an inexpensive material that easily recirculates magnetic
flux.
[0015] The bicycle generator hub pertaining to a fourth aspect of
the present invention is the bicycle generator hub according to the
third aspect of the present invention, wherein the first and second
magnetic flux recirculation members are disposed on the first and
second cap members, which rotate together with the magnets. The
first and second magnetic flux recirculation members extend toward
the sides of the coil. The first and second magnetic flux
recirculation members can easily face the coil because they are
placed between the cylinder member and the first and second
bearings. Because the first and second magnetic flux recirculation
members are disposed on the first and second cap members,
respectively, the magnetic flux can be easily recirculated to the
coil.
[0016] The bicycle generator hub pertaining to a fifth aspect of
the present invention is the bicycle generator hub according to the
fourth aspect of the present invention, wherein the first and
second magnetic flux recirculation members are integrally formed
with the cap members. Because the first and second magnetic flux
recirculation members are integrally formed with the first and
second cap members, the first and second magnetic flux
recirculation members can be realized using a simple
construction.
[0017] The bicycle generator hub pertaining to a sixth aspect of
the present invention is the bicycle generator hub according to the
third aspect of the present invention, wherein the first and second
magnetic flux recirculation members extend from the sides of the
coil toward the first and second cap members. In this case, the
magnetic flux that leaks from the coil can be easily returned to
the coil via the first and second cap members.
[0018] The bicycle generator hub pertaining to a seventh aspect of
the present invention is the bicycle generator hub according to any
of the third through sixth aspects of the present invention,
wherein the cylindrical member is made of an aluminum alloy and the
first and second cap members are made of an iron-based magnetic
metal. The magnetic flux passes through the first and second cap
members during the recirculation process. Because the cylindrical
member is disposed close to the magnets and is made of an aluminum
alloy, the magnetic flux from the magnets is not easily dispersed.
Dispersion of the magnetic flux is prevented because the first and
second cap members are made of an inexpensive iron-based magnetic
material that easily conducts the magnetic flux. The construction
of the first and second cap members facilitates recirculation of
the magnetic flux to the coil. In addition, costs are reduced.
[0019] The bicycle generator hub pertaining to an eighth aspect of
the present invention is the bicycle generator hub according to any
of the third through sixth aspects of the present invention,
wherein both the cylindrical member and the first and second cap
members are made of an iron-based magnetic metal. In this case,
costs are further reduced because the entire hub shell is made of
an inexpensive iron-based magnetic metal.
[0020] The bicycle generator hub pertaining to a ninth aspect of
the present invention is the bicycle generator hub according to any
of the third through sixth aspects of the present invention,
wherein the first and second magnetic flux recirculation members
are mounted to the hub shaft such that they extend toward the sides
of the coil. In this case, the first and second magnetic flux
recirculation members do not rotate relative to the coil because
the first and second magnetic flux recirculation members are
mounted to the hub shaft with the coil. With this construction, a
gap between the first and second magnetic flux recirculation
members and the coil is provided. The gap can be gradually reduced
to the extent that the first and second magnetic flux recirculation
members are brought into contact with the coil in order to improve
recirculation of the magnetic flux.
[0021] The bicycle generator hub pertaining to a tenth aspect of
the present invention is the bicycle generator hub according to the
first aspect of the present invention, wherein the first and second
magnetic flux recirculation members are disposed on either the hub
shaft or the hub shell with the ends thereof positioned close to
the sides of the coil.
[0022] In the bicycle generator hub of the tenth aspect, during
rotation of the hub shell, the magnetic flux that leaks from the
coil is returned to the coil by the first and second magnetic flux
recirculation members, which are disposed on the hub shell or the
hub shaft. Each of the first and second magnetic flux recirculation
members have and end portion that is disposed proximate to the
coil. The magnetic flux is returned via one of two paths. The first
path is through the hub shaft, the first and second bearings, the
hub shell and the first and second magnetic flux recirculation
members. The second path is through the hub shaft and the first and
second magnetic flux recirculation members. As a result, regardless
of the material in the hub shell, the amount of magnetic flux
passing through the coil increases. The increase in the amount of
magnetic flux increases power generation efficiency and reduces
costs.
[0023] The bicycle generator hub pertaining to an eleventh aspect
of the present invention is a bicycle generator hub according to
the first aspect of the present invention, wherein each of the
first and second magnetic flux recirculation members have a first
end portion that contacts the coil and a second end portion that is
disposed proximate to one of the hub shell and hub shaft. The first
and second magnetic flux recirculation members return the leaked
magnetic flux to the coil.
[0024] In the bicycle generator hub of the eleventh aspect of the
present invention, during rotation of the hub shell, the magnetic
flux that leaks from the coil is returned to the coil by the first
and second magnetic flux recirculation members. Each of the first
and second magnetic flux recirculation members has a first end
portion in contact with the coil and a second end portion that is
disposed proximate to one of the hub shell and the hub shaft.
[0025] The bicycle generator hub pertaining to a twelfth aspect of
the present invention is the bicycle generator hub according to the
tenth or eleventh aspect of the present invention, wherein the
first and second magnetic flux recirculation members are made of an
iron-based metal. In this case, the first and second magnetic flux
recirculation members can efficiently recirculate the magnetic
flux.
[0026] The bicycle generator hub pertaining to a thirteenth aspect
of the present invention is the bicycle generator hub according to
any of the tenth through twelfth aspects of the present invention,
wherein the first and second magnetic flux recirculation members
comprise annular members disposed around the hub shaft. In this
case, because the end portions of the first and second magnetic
flux recirculation members are uniformly close to the hub shell,
hub shaft or coil, the magnetic flux can be efficiently
recirculated.
[0027] The bicycle generator hub pertaining to a fourteenth aspect
of the present invention is the bicycle generator hub according to
any of the tenth through thirteenth aspects of the present
invention, wherein the first and second magnetic flux recirculation
members comprise rod-shaped members disposed around the hub shaft.
In this case, the first and second magnetic flux recirculation
members have a simple construction and are lightweight.
[0028] The bicycle generator hub pertaining to a fifteenth aspect
of the present invention is a bicycle generator hub that is mounted
to a bicycle frame, and includes a hub shaft, a hub shell, first
and second bearings and a generator mechanism. The hub shaft is
configured and arranged to be non-rotatably mounted to a bicycle
frame. The hub shell is rotatably mounted around the hub shaft. The
hub shell has a cylindrical member and first and second cap
members. The first and second bearings are disposed between the hub
shell and the hub shaft. The generator mechanism has a coil mounted
to the hub shaft. The generator mechanism has magnets that are
disposed opposite the coil on an inner circumferential surface of
the hub shell. The generator mechanism generates electric power
from rotation of the hub shell relative to the hub shaft. The first
and second cap members are disposed between the first and second
bearings, respectively, and the cylindrical member. Each of the
first and second cap members are bent towards the coil to form
first and second magnetic flux recirculation members, respectively.
Each of the first and second magnetic flux recirculation members
has an end portion that is proximate to the coil.
[0029] In the bicycle generator hub of the fifteenth aspect of the
present invention, during the rotation of the hub shell, the
magnetic flux that leaks from the coil is returned to the coil by
the first and second magnetic flux recirculation members, which are
formed from the first and second cap members, respectively. As a
result, regardless of the material of the hub shell, the amount of
magnetic flux passing through the coil increases. This increase in
the amount of magnetic flux increases power generation efficiency
and reduces costs. Furthermore, the first and second magnetic flux
recirculation members are easily formed by bending the first and
second cap members.
[0030] These and other objects, features, aspects and advantages of
the present invention will become apparent to those skilled in the
art from the following detailed description, which, taken in
conjunction with the annexed drawings, discloses preferred
embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Referring now to the attached drawings which form a part of
this original disclosure:
[0032] FIG. 1 is a side elevational view of a bicycle equipped with
a bicycle generator hub in accordance with a first embodiment of
the present invention;
[0033] FIG. 2 is a partial cross-sectional view of the bicycle
generator hub coupled to the front fork of the bicycle illustrated
in FIG. 1 in accordance with the first embodiment of the present
invention;
[0034] FIG. 3 is an enlarged partial cross-sectional view of a
generator hub evaluation mechanism used in experiments to establish
the effectiveness of the present invention;
[0035] FIG. 4 is a graph showing results from experiments with the
generator hub evaluation mechanism of FIG. 3 that is made of
aluminum alloy and structural carbon steel;
[0036] FIG. 5 is a graph showing results from experiments with the
generator hub evaluation mechanism of FIG. 3 that is made of
structural carbon steel;
[0037] FIG. 6 is a partial cross-sectional view of a bicycle
generator hub coupled to the front fork of the bicycle illustrated
in FIG. 1 in accordance with a second embodiment of the present
invention;
[0038] FIG. 7 is a partial cross-sectional view of a bicycle
generator hub coupled to the front fork of the bicycle illustrated
in FIG. 1 in accordance with a third embodiment of the present
invention;
[0039] FIG. 8 is a partial cross-sectional view of a bicycle
generator hub coupled to the front fork of the bicycle illustrated
in FIG. 1 in accordance with a fourth embodiment of the present
invention;
[0040] FIG. 9 is a partial cross-sectional view of a bicycle
generator hub coupled to the front fork of the bicycle illustrated
in FIG. 1 in accordance with a fifth embodiment of the present
invention; and
[0041] FIG. 10 is partial cross-sectional view of a bicycle
generator hub coupled to the front fork of the bicycle illustrated
in FIG. 1 in accordance with a sixth embodiment of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Selected embodiments of the present invention will now be
explained with reference to the drawings. It will be apparent to
those skilled in the art from this disclosure that the following
descriptions of the embodiments of the present invention are
provided for illustration only and not for the purpose of limiting
the invention as defined by the appended claims and their
equivalents.
[0043] Referring initially to FIG. 1, a bicycle with a bicycle
generator hub 8 is illustrated in accordance with a first
embodiment of the present invention. The bicycle is lightweight and
includes a frame 1, a handle unit 4, a drive unit 5, a front wheel
6, a rear wheel 7, a saddle 11 and a lamp 41. The frame 1 has a
double-loop frame body 2 and a front fork 3. The front wheel 6
includes a bicycle generator hub 8.
[0044] The double-loop frame body 2 of the frame 1 is built by
welding pipes together. Various units such as the saddle 11 and the
drive unit 5 are mounted to the frame body 2. The front fork 3 is
movably mounted to the front part of the frame body 2 such that it
can rotate around an angled axis. The front wheel 6 includes a rim
6a and a plurality of spokes 6b extending between the generator hub
8 and the rim 6a. The front wheel 6 is mounted to the front fork 3
by the generator hub 8. The lamp 41 is mounted to the front fork 3
at roughly the midpoint thereof.
[0045] The handle unit 4 has a handle stem 14, a handlebar 15, a
pair of brake levers 16 (only one side shown), a pair of grips 17
(only one side shown) and a gear shift operation unit 20. The brake
levers 16 and the grips 17 are mounted to either end of the
handlebar 15. The gear shift operation unit 20 is integrally formed
with the right brake lever 16. The handle stem 14 is secured to the
top of the front fork 3. The handlebar 15 is secured to the upper
end of the handle stem 14 in a conventional manner.
[0046] The drive unit 5 basically has a gear crank 37, a chain 38,
and an internal gear shift hub 10. The internal gear shift hub 10
is a three-speed internal gear shift hub having three gears. The
internal gear shift hub 10 is shifted by operating the gear shift
operation unit 20. The internal gear shift hub 10 is mounted to the
rear wheel 7. The gear crank 37 is disposed at the bottom of the
frame body 2 (on a hanger unit). The chain 38 is suspended around
the gear crank 37.
[0047] Referring to FIG. 2, the bicycle generator hub 8 rotatably
mounts the front wheel 6 to the front fork 3. The bicycle generator
hub 8 includes a first end portion 22, a second end portion 24, a
hub shaft 50, a hub shell 51, first and second bearings 52 and 53,
a generator mechanism 54 and first and second magnetic flux
recirculation members 55 and 56. The hub shaft 50 is non-rotatably
mounted to the front fork 3. The hub shell 51 is disposed coaxially
around the outer circumference of the hub shaft 50. The first and
second bearings 52 and 53 are disposed between the hub shaft 50 and
the hub shell 51. The first and second bearings 52 and 53 enable
the hub shell 51 to be mounted such that it can rotate relative to
the hub shaft 50. The generator mechanism 54 generates power from
rotation of the hub shell 51 relative to the hub shaft 50. The
first and second magnetic flux recirculation members 55 and 56 are
integrally formed with the hub shell 51, as shown in FIG. 2.
[0048] The hub shaft 50 includes first and second small diameter
threads 50a and 50b, a large diameter thread 50c and a wiring path
groove 50d. The first and second small diameter threads 50a and 50b
are each located at the first and second end portions 22 and 24,
respectively. The large diameter threads 50c are located between
the first and second small diameter threads 50a and 50b. The hub
shaft 50 is magnetic and is made of an iron-based metal, such as
structural carbon steel or a structural steel alloy. The first and
second small-diameter threads 50a and 50b secure the hub shaft 50
to the front fork 3. The first and second small-diameter threads
50a and 50b secure the first and second bearings 52 and 53,
respectively, between the hub shaft 50 and the hub shell 51. The
large-diameter threads 50c provide a mounting area for the
generator mechanism 54. The wiring path groove 50d is formed in the
outer circumferential surface of the hub shaft 50 and runs from the
mounting area of the generator mechanism 54 to the second end
portion 24 (the right side as viewed in FIG. 2). The hub shaft 50
is non-rotatably secured to the ends of the front fork 3 by first
and second nuts 57 and 58. The first and second small-diameter
threads 50a and 50b are threaded into the first and second nuts 57
and 58, respectively. An external current draw terminal 59 is
mounted to the second end portion 24 of the hub shaft 50. The
external current draw terminal 59 is connected to the lamp 41, for
example. The external current draw terminal 59 is electrically
connected to the generator mechanism 54 via internal wiring 40. The
internal wiring 40 is preferably located in the wiring path groove
50d.
[0049] As is illustrated in FIG. 2, the hub shell 51 has a
cylindrical hub drum or cylindrical member 60 and first and second
or left and right cap members 61 and 62. The first and second cap
members 61 and 62 are non-rotatably mounted at either end of the
hub drum 60. The hub drum 60 has a small-diameter area proximate
the first end portion 22 of the bicycle generator hub 8. The hub
drum 60 also has a large-diameter area that is adjacent to the
small-diameter area and extends to the second end portion 24 of the
bicycle generator hub 8. The small-diameter area of the hub drum 60
has a smaller diameter than the large-diameter area of the hub drum
60. The hub drum 60 is made of an aluminum alloy, for example. The
generator mechanism 54 is disposed between the large-diameter area
of the hub drum 60 and the hub shaft 50. At the end of the hub drum
60, closest to the second end portion 24, a hub flange 60a is
formed such that it extends outward in the radial direction from
the large-diameter area of the hub drum 60. The hub flange 60a
engages the spokes 6b that connect to the rim 6a of the front wheel
6.
[0050] The first cap member 61 is non-rotatably crimped to the
small-diameter area of the hub drum 60 and fastened via serrations,
for example. The first cap member 61 is made of an iron-based
metal, such as structural carbon steel or a structural steel alloy.
The first cap member 61 has a hub flange 61a, a first disk 61b, and
a cylindrical first connector 61c. The first bearing 52 is mounted
inside the inner circumference of the first disk 61b. In addition,
the first magnetic flux recirculation member 55 is integrally
formed as a cylinder. The hub flange 60a engages with the spokes
6b. The first disk 61b is disposed such that it extends from the
hub flange 61a to a mounting area of the first bearing 52. The
cylindrical first connector 61c is formed to extend from the radial
midsection of the first disk 61b such that it faces the hub drum
60.
[0051] The second cap member 62 is made of an iron-based metal
having a magnetic property such as structural carbon steel or a
structural steel alloy. The second cap member 62 engages with an
inner circumference of the right side of the hub drum 60 via
threads, for example. The second cap member 62 has a second
connector 62a that is disposed on the inner circumferential surface
of the hub drum 60 and threads into the hub drum 60. The second cap
member 62 also has a second disk 62b that extends from the second
connector 62a to a mounting area of the second bearing 53. The
second bearing 53 is mounted inside the inner circumference of the
second disk 62b. In addition, the second magnetic flux
recirculation member 56 is integrally formed as a cylinder.
[0052] The first bearing 52 has a first cup 52a, a first crown cone
52b, and a plurality of first steel balls 52c. The second bearing
53 has a second cup 53a, a second crown cone 53b, and a plurality
of second steel balls 53c. The first and second cups 52a and 53a
are mounted to the first and second cap members 61 and 62,
respectively. The first and second crown cones 52b and 53b are
threaded onto the first and second small-diameter threads 50a and
50b, respectively, of the hub shaft 50. The first steel balls 52c
are disposed between the first cup 52a and the first crown cone
52b. The first cup 52a and the first crown cone 52b are in contact
with the first steel balls 52c. The second steel balls 53c are
disposed between the second cup 53a and the second crown cone 50b.
The second cup 53a and the second crown cone 53b are in contact
with the second steel balls 53c.
[0053] The generator mechanism 54 is mounted on the large-diameter
threads 50c. The generator mechanism 54 includes a coil 70 and a
magnet unit 71. The coil 70 of the generator mechanism 54 has a
claw-pole type coil that is non-rotatably mounted to the hub shaft
50. The coil 70 is non-rotatably secured to the hub shaft 50 by
first and second nut members 72 and 73 that are threaded onto the
large-diameter threads 50c. The coil 70 includes a pair of
claw-type secured yokes 70a and 70b disposed in an alternating
fashion. The coil 70 further includes a coil unit 70c and a core
yoke 70d. The coil unit 70c is disposed between the secured yokes
70a and 70b. The core yoke 70d is disposed inside the coil unit
70c. The coil 70 is electrically connected to the external current
draw terminal 59 via internal wiring 40. The first magnetic flux
recirculation member 55 extends from the mounting area of the first
bearing 52 towards the coil 70. Likewise, the second magnetic flux
recirculation member 56 extends from the mounting area of the
second bearing 53 towards the coil 70.
[0054] The magnet unit 71 of the generator mechanism 54 is disposed
on the inner circumferential surface of the hub drum 60 of the hub
shell 51 such that it faces the coil 70. The magnet unit 71 has a
cylindrical rotating yoke 74 and multiple (four, for example)
permanent magnets 75. The cylindrical rotating yoke 74 is press-fit
into the inner circumferential surface of the hub drum 60. The
magnets 75 are mounted circumferentially on the inner
circumferential surface of the rotating yoke 74 with gaps
therebetween. The rotating yoke 74 is made of an iron-based metal,
such as structural carbon steel or a structural steel alloy. Each
permanent magnet 75 has alternating N poles and S poles such that a
total of twenty-eight poles can face the secured yokes 70a and
70b.
[0055] The first and second magnetic flux recirculation members 55
and 56 are cylindrical members that are integrally formed with the
first and second cap members 61 and 62, respectively. Each of the
first and second magnetic flux recirculation members 55 and 56 has
an end portion that is disposed proximate to the coil 70.
Specifically, the distance between the ends of the first and second
magnetic flux recirculation members 55 and 56 and the sides of the
coil 70 ranges from 1 mm to 12 mm. The first and second magnetic
flux recirculation members 55 and 56 are integrally formed with the
first and second cap members 61 and 62, respectively, and therefore
rotate when the bicycle is moving. Accordingly, if the distance is
smaller than 1 mm, there is a danger that the end portions of the
first and second magnetic flux recirculation members 55 and 56 that
are proximate to the coil 70 will contact the sides of the coil 70.
The danger depends on the degree of precision with which the
bicycle generator hub 8 was assembled.
[0056] The generation of power by the bicycle generator hub 8 will
now be described. When the front wheel 6 rotates, the magnet unit
71 rotates as well. When this occurs, the magnet unit 71 rotates
around the secured yokes 70a and 70b. As a result, when one of the
secured yokes 70a or 70b receives N-pole magnetic flux from the
magnet unit 71, the other secured yoke 70a or 70b receives S-pole
magnetic flux. Conversely, when one of the securing yokes 70a or
70b receives S-pole magnetic flux from the magnet unit 71, the
other secured yoke 70a or 70b receives N-pole magnetic flux. In
other words, due to the rotation of the magnet unit 71 around the
secured yokes 70a and 70b, the coil 70 repeatedly alternates
between a first state and a second state. In a first state, for
example, the secured yoke 70a receives N-pole magnetic flux and the
secured yoke 70b receives S-pole magnetic flux. In a second state,
for example, the secured yoke 70a receives S-pole magnetic flux and
the secured yoke 70b receives N-pole magnetic flux. Referring to
FIG. 2, alternating magnetic flux is generated in the axial 0-0
direction in the core yoke 70d, which electrically connects the
secured yokes 70a and 70b. As a result of the alternating magnetic
flux being generated inside the coil unit 70c, electric current is
generated in the coil unit 70c. Accordingly, electric power is
generated and sent from the external current draw terminal 59 to
the lamp 41 via the internal wiring 40.
[0057] When power is generated, part of the alternating magnetic
flux leaks out into the hub shaft 50 from the coil 70, as shown by
the arrows A and B in FIG. 2. However, the leaked magnetic flux
reaches the first and second magnetic flux recirculation members 55
and 56 via the first and second bearings 52 and 53 and the first
and second cap members 61 and 62, respectively. The leaked magnetic
flux returns to the coil 70 via the end portions of the first and
second magnetic flux recirculation members 55 and 56. As a result,
the magnetic flux that passes through the coil unit 70c increases,
thereby increasing power generating efficiency.
[0058] A generator hub evaluation mechanism 108, shown in FIG. 3,
was used to perform experiments in order to confirm the unique
characteristics of the invention detailed above. The generator hub
evaluation mechanism 108 includes a hub shaft 150, a cylindrical
hub shell 151, a first bearing 152, a second bearing (not shown), a
first magnetic flux recirculation member 155 and a second magnetic
flux recirculation member (not shown). The hub shell 151 has a
cylindrical hub drum 160, a first cap member 161 and a second cap
member (not shown). The first and second cap members 161 are
disposed at either end of the hub drum 160. The first magnetic flux
recirculation member 155 is disposed in a mounting area of the
first bearing 152 of the first cap member 161. The first magnetic
flux recirculation member 155 is structured to move in the hub
axial direction. The generator hub evaluation mechanism 108 further
includes a coil 170 and a magnet unit 171. The coil 170 is
non-rotatably mounted to the hub shaft 150. The magnet unit 171 is
secured to an inner circumferential surface of the hub drum
160.
[0059] FIGS. 4 and 5 show graphs measuring the relationship between
the rotation rate and the rate of decline in generated voltage
using the generator hub evaluation mechanism 108 shown in FIG.
3.
[0060] FIG. 4 is a graph representing a situation in which the hub
drum 160 is made of an aluminum alloy (A6061, for example) and
first and second cap members 161 are made of structural carbon
steel (S15C, for example). FIG. 5 is a graph representing a
situation in which both the hub drum 160 and the first and second
cap members 161 are made of structural carbon steel (S 15C, for
example). Here, experiments were performed in which first and
second magnetic flux recirculation members 155 were made of carbon
steel. The first and second magnetic flux recirculation members 155
were placed in various positions. The relationship between the
rotation rate and the rate of voltage decline was measured for the
various positions.
[0061] In FIG. 4, the line marked by the letter `X` shows the case
in which a 2 mm gap is between the coil 170 and an end portion of
each of the first magnetic flux recirculation member 155 and second
magnetic flux recirculation member. The possible positions of the
end portion of the first magnetic flux recirculation member 155 are
indicated by a broken line in FIG. 3. The 2 mm position is
indicated by the vertical broken line in FIG. 3. The line marked by
asterisks in FIG. 4 shows an instance in which the gap was 12.5 mm.
The position of the first magnetic flux recirculation member 155
for the 12.5 mm gap is indicated by the solid lines in FIG. 3. The
line marked by diamonds in FIG. 4 shows the case in which there was
not a first magnetic flux recirculation member (FMFRM) 155. The
line marked by triangles in FIG. 4 shows the case in which the gap
between each of the first and second magnetic flux recirculation
members 155 and the magnet unit 171 was 12 mm. The line marked by
squares in FIG. 4 shows the case in which the gap between each of
the first and second magnetic flux recirculation members 155 and
the magnet unit 171 was a mere 1.5 mm. As is clear from FIG. 4, the
rate of voltage decline increases as the magnet unit 171 becomes
closer to the first and second magnetic flux recirculation members
155. This is thought to be due to the dispersal of the magnetic
field generated from the magnet unit 171. The rate of voltage
decline decreases as the first and second magnetic flux
recirculation members 155 are placed closer to the coil 170. The
fact that the rate of voltage decline becomes positive appears to
be a measurement error. As a result, it was confirmed that if first
and second magnetic flux recirculation members 155 are to be used,
it is more effective to place them next to the coil 170 than next
to the magnet unit 171.
[0062] In FIG. 5, the line marked by triangles shows the case in
which a 2 mm gap is between the coil 170 and an end portion of each
of the first and second magnetic flux recirculation members 155.
The line marked by diamonds in FIG. 5 shows the case in which no
first magnetic flux recirculation member (FMFRM) 155 was used. The
line marked by squares in FIG. 5 shows the case in which the gap
between the magnet unit 171 and each of the first and second
magnetic flux recirculation members 155 was 1.5 mm.
[0063] As is clear from these two graphs, when the first and second
magnetic flux recirculation members 155 come close to the coil 170,
the rate of voltage decline decreases. When the first and second
magnetic flux recirculation members 155 come close to the magnet
unit 171, the rate of voltage decline increases. This tendency
holds true even if the material used for the hub drum 160 is
changed. As a result, it was determined that the power generation
efficiency increases regardless of the material of the hub shell
simply by bringing the end portion of the first and second magnetic
flux recirculation members 155 closer to the coil 170.
[0064] During rotation of the magnet unit 171, the leaked magnetic
flux is returned to the coil 170 by the first and second magnetic
flux recirculation members 155 via the hub shaft 150. Accordingly,
the amount of magnetic flux passing through the coil 170 increases.
The increased amount of magnetic flux passing through the coil 170
prevents deterioration in power generation efficiency and reduces
costs.
[0065] As used herein to describe the present invention, the
following directional terms "forward, rearward, above, downward,
vertical, horizontal, below and transverse" as well as any other
similar directional terms refer to those directions of a bicycle
equipped with the present invention. Accordingly, these terms, as
utilized to describe the present invention should be interpreted
relative to a bicycle equipped with the present invention.
Second Embodiment
[0066] Referring now to FIG. 6, a bicycle generator hub 208 in
accordance with a second embodiment will now be explained. In view
of the similarity between the first and second embodiments, the
parts of the second embodiment that are identical to the parts of
the first embodiment will be given the same reference numerals as
the parts of the first embodiment. Moreover, the descriptions of
the parts of the second embodiment that are identical to the parts
of the first embodiment may be omitted for the sake of brevity.
[0067] The bicycle generator hub 208 is essentially the same as in
the first embodiment except that the first and second magnetic flux
recirculation members 255 and 256 are not directly attached to the
first and second cap members 261 and 262. Referring to FIG. 6, the
first and second magnetic flux recirculation members 255 and 256
are annular members that are threaded onto the large-diameter
thread 50c of the hub shaft 50. The coil 70 is located on the hub
shaft 50 between the first and second nut members 72 and 73. The
coil 70 is non-rotatably secured to the hub shaft 50 by the first
and second nut members 72 and 73. The first and second magnetic
flux recirculation members 255 and 256 abut the first and second
nut members 72 and 73, respectively, on their outer axial side.
Each of the first and second magnetic flux recirculation members
255 and 256 has an end portion that is proximate to the coil 70.
The first and second magnetic flux recirculation members 255 and
256 are cylindrical members. In this embodiment, the first and
second magnetic flux recirculation members 255 and 256 do not
rotate relative to the coil 70 because they are directly attached
to the hub shaft 50. Because of this, the end portions of the first
and second magnetic flux recirculation members 255 and 256 can be
brought closer to the coil 70 and can even be brought into contact
with the coil 70.
Third Embodiment
[0068] Referring now to FIG. 7, a bicycle generator hub 308 in
accordance with a third embodiment will now be explained. In view
of the similarity between the first and third embodiments, the
parts of the third embodiment that are identical to the parts of
the first embodiment will be given the same reference numerals as
the parts of the first embodiment. Moreover, the descriptions of
the parts of the third embodiment that are identical to the parts
of the first embodiment may be omitted for the sake of brevity.
[0069] The bicycle generator hub 308 is essentially the same as in
the first embodiment except that the first and second magnetic flux
recirculation members 355 and 356 contact the coil 70 and are
proximate to the first and second cap members 361 and 362.
Specifically, as is illustrated in FIG. 7, each of the first and
second magnetic flux recirculation members 355 and 356 has a first
end portion that contacts the coil 70 and a second end portion that
is disposed proximate to the hub shell 351. More specifically, each
of the second end portions of the first and second magnetic flux
recirculation members 355 and 356 is disposed proximate to the
first and second cap members 361 and 362, respectively.
[0070] The first and second magnetic flux recirculation members 355
and 356 are annular members disposed around the circumference of
the hub shaft 50. The coil 70 is located on the hub shaft 50
between the first and second nut members 72 and 73. The coil 70 is
non-rotatably secured to the hub shaft 50 by the first and second
nut members 72 and 73. In FIG. 7, the first and second magnetic
flux recirculation members 355 and 356 are integrally formed with
the first and second nut members 72 and 73. However, it will be
apparent to one of skill in the art that the first and second
magnetic flux recirculation members 355 and 356 may be formed
independently of the first and second nut members 72 and 73. The
first and second magnetic flux recirculation members 355 and 356
have first and second tool engagement areas 355a and 356a,
respectively. The first and second tool engagement areas 355a and
356a provide a means for various tools to engage the first and
second magnetic flux recirculation members 355 and 356 and the
first and second nut members 72 and 73. The first and second tool
engagement areas 355a and 356a are formed on outer circumferential
surfaces of the first and second magnetic flux recirculation
members 355 and 356, respectively. The first and second tool
engagement areas 355a and 356a have multiple protrusions around the
circumferential direction.
Fourth Embodiment
[0071] Referring now to FIG. 8, a bicycle generator hub 408 in
accordance with a fourth embodiment will now be explained. In view
of the similarity between the first and fourth embodiments, the
parts of the fourth embodiment that are identical to the parts of
the first embodiment will be given the same reference numerals as
the parts of the first embodiment. Moreover, the descriptions of
the parts of the fourth embodiment that are identical to the parts
of the first embodiment may be omitted for the sake of brevity.
[0072] The bicycle generator hub 408 is essentially the same as in
the first embodiment except that the first and second magnetic flux
recirculation members 455 and 456 contact the coil 70 and are
proximate to the hub shaft 50. Specifically, as is illustrated in
FIG. 8, each of the first and second magnetic flux recirculation
members 455 and 456 has a first end portion that contacts the coil
70 and a second end portion that is disposed proximate to the hub
shaft 50. The coil 70 is located on the hub shaft 50 between the
first and second nut members 72 and 73. In this embodiment, the
first and second magnetic flux recirculation members 455 and 456 as
well as the coil 70 are secured using the first and second nut
members 72 and 73, respectively.
[0073] The first and second magnetic flux recirculation members 455
and 456 are annular members disposed around the circumference of
the hub shaft 50. The first and second magnetic flux recirculation
members 455 and 456 have first and second ring-shaped securing
units 455a and 456a and first and second rod-shaped members 455b
and 456b, respectively. The first and second ring-shaped securing
units 455a and 456a are respectively secured to the first and
second nut members 72 and 73. The first and second rod-shaped
members 455b and 456b extend in the radial direction from the first
and second securing units 455a and 456a, respectively. Each of the
first and second rod-shaped members 455b and 456b are bent twice
such that each of the second end portions of the first and second
magnetic flux recirculation members 455 and 456 is proximate to the
hub shaft 50.
Fifth Embodiment
[0074] Referring now to FIG. 9, a bicycle generator hub 508 in
accordance with a fifth embodiment will now be explained. In view
of the similarity between the first and fifth embodiments, the
parts of the fifth embodiment that are identical to the parts of
the first embodiment will be given the same reference numerals as
the parts of the first embodiment. Moreover, the descriptions of
the parts of the fifth embodiment that are identical to the parts
of the first embodiment may be omitted for the sake of brevity.
[0075] The bicycle generator hub 508 is essentially the same as in
the first embodiment except that the first magnetic flux
recirculation member 555 and the second magnetic flux recirculation
member (not shown) are formed by bending a portion of the hub shell
551. Specifically, as is illustrated in FIG. 9, the first cap
member 561 of the hub shell 551 is formed via press-molding. More
specifically, the first magnetic flux recirculation member 555 is
formed by bending a center portion of the first cap member 561 in
the shape of the letter `U`, for example. The first magnetic flux
recirculation member 555 is bent toward the coil 70 such that a
portion of the first magnetic flux recirculation member 555 is
proximate to the coil 70.
Sixth Embodiment
[0076] Referring now to FIG. 10, a bicycle generator hub 608 in
accordance with a sixth embodiment will now be explained. In view
of the similarity between the first and sixth embodiments, the
parts of the sixth embodiment that are identical to the parts of
the first embodiment will be given the same reference numerals as
the parts of the first embodiment. Moreover, the descriptions of
the parts of the sixth embodiment that are identical to the parts
of the first embodiment may be omitted for the sake of brevity.
[0077] The bicycle generator hub 608 is essentially the same as in
the first embodiment except that the first magnetic flux
recirculation member 655 and the second magnetic flux recirculation
member (not shown) are formed by bending a portion of the hub shell
651. Specifically, as is illustrated in FIG. 10, the first cap
member 661 of the hub shell 651 is formed by press-molding. More
specifically, the first magnetic flux recirculation member 655 is
formed by bending a center portion of the first cap member 661 such
that it extends toward the coil 70 from the bearing mounting area
of the first cap member 661. The first magnetic flux recirculation
member 655 is substantially in the shape of an "I". An end portion
of the first magnetic flux recirculation member 655 is proximate to
the side of the coil 70, as shown in FIG. 10.
[0078] In the above embodiments, first and second magnetic flux
recirculation members are used. However, where the generator
mechanism is disposed closer to one end of the hub shell, only one
magnetic flux recirculation member is needed. The single magnetic
flux recirculation member is preferably disposed on the side of the
generator mechanism in which there is a larger gap between the
generator mechanism and the end of the hub shell.
[0079] In the above embodiments, the present invention was
described in relation to the front wheel 6, but it will be clear to
one of skill in the art that the present invention may also be
applied to the rear wheel 7.
[0080] In understanding the scope of the present invention, the
term "comprising" and its derivatives, as used herein, are intended
to be open ended terms that specify the presence of the stated
features, elements, components, groups, integers, and/or steps, but
do not exclude the presence of other unstated features, elements,
components, groups, integers and/or steps. The foregoing also
applies to words having similar meanings such as the terms,
"including", "having" and their derivatives. Also, the terms
"member" or "element" when used in the singular can have the dual
meaning of a single part or a plurality of parts. Finally, terms of
degree such as "substantially", "about" and "approximately" as used
herein mean a reasonable amount of deviation of the modified term
such that the end result is not significantly changed. These terms
of degree should be construed as including a deviation of at least
.+-.5% of the modified term if this deviation would not negate the
meaning of the word it modifies.
[0081] While only selected embodiments have been chosen to
illustrate the present invention, it will be apparent to those
skilled in the art from this disclosure that various changes and
modifications can be made herein without departing from the scope
of the invention as defined in the appended claims. Furthermore,
the foregoing descriptions of the embodiments according to the
present invention are provided for illustration only, and not for
the purpose of limiting the invention as defined by the appended
claims and their equivalents.
* * * * *